Professional Documents
Culture Documents
Process Mineralogy
for Metals
Raw materials must be seen from the perspective of local availability and market needs.
Mining engineers must be prepared to see beyond the mining viewpoint and apply mineral
process techniques to transform any kind of raw materials (including garbage) into saleable
products.
Mining engineers must be familiar with the uses of raw materials in different industrial
sectors to be able to adapt, modify and create new uses.
A holistic vision will also help to address concerns about the environment.
"Ore is a mineral from which it is possible to produce metal by using technological
methods that already exist or can reasonably be developed. By convention there is no "clay
ore" or "gypsum ore". Minerals become ores when technological developments allow them
to be mined and treated successfully." Jones (1987)
by the final use of the material, either structural (pieces, objects, ...) or functional
(electronic, magnetic, optical, biomaterials, etc.)
Raw material will be transformed based on market needs and available technology.
Process mineralogy combines mineralogical techniques with mineral process unit operations
to identify minerals, their associations and characteristics in order to:
Process mineralogy will not provide all the answers but will give good hints at the early
stages of a geological exploration project.
ores (small amount of the metallic mineral of interest: with exception of Fe and Mn,
ore-minerals occur in ore deposits in small quantities, usually < 20%; e.g. metal grades of
some ore deposits: 0.4% Cu, 12% Zn, 7% Pb, 4% Ni, 3 ppm Au, 50 ppm Ag.), or
Element distribution in minerals and sized fractions (gives indication about what
are the substance-bearing minerals, mineral liberation and how mass can be eliminated)
The bottom line is to predict and explain performance when a mineral is subjected to a
physical or chemical process.
The main techniques applied to process mineralogy are:
instrumental analysis (XRD, SEM, DTA, TG, IR, XRF, AAS, etc ...)
Principle
Purpose
Polarized Optical
Microscopy
X-ray Diffraction
(XRD)
Scanning Electron
Microscopy
(SEM)
Infrared
Spectroscopy
(IRS)
X-ray
Photoelectron
Spectroscopy
(XPS)
and Auger
Spectroscopy
Transmission
Electron
Microscopy
(TEM)
Thermal Analysis
(Termogravimetry
TG,
Differential
Thermal Analysis DTA)
Principle
Purpose
Qualitative and
quantitative analysis of
elements with atomic
number between 6 and
92
Atomic Absorption
Spectroscopy
(AAS)
Sequential analysis of
elements (mostly
cations). For gold
analysis, a fusion
procedure + acid
digestion (fire assay)
precedes the AAS
analysis.
Inductively
Coupled PlasmaAtomic Emission
Spectroscopy
(ICP-AES)
Simultaneous analysis of
elements (mostly
cations).
Ultra-violet visible
Spectroscopy
The absorption of
characteristic
wavelengths allows
quantifying the
concentration of that
specific molecule in a
solution.
Selective Chemical
Extraction
Identify metal-bearing
minerals: exploration
and environmental
purposes. Bioavailability
of heavy metals can be
inferred.
Atomic Spectroscopy
An element to be analyzed is converted
into a neutral atomic or ionic vapor.
Electromagnetic radiation absorbed or
emitted by electrons during orbital
transitions is the analytical signal of
interest.
Atomic Absorption Spectrometry and
Atomic Emission Spectroscopy (e.g. ICPAES) are examples of atomic spectroscopy
techniques.
Mineralogical Analysis
Qualitative and Quantitative Analysis
There are approximately 3500 known minerals. This number is slowly increasing as new
minerals are discovered by modern analytical methods and new mineralogical environments.
Only 250 to 300 minerals form common commercial products or occur in significant
proportions in ores or mineral deposits. However it is important to know the gangue minerals,
as they can contaminate concentrates or final products as well as cause impact to the
environment.
There are many diagnostic properties usually applied to hand specimens: crystal habits,
cleavage, fracture, hardness, specific gravity, color, streak, luster, etc. Some of these
properties bring more certainty to mineral identification than others.
In process mineralogy, we need to identify and quantify all minerals present in a
representative sample.
The main identification techniques are:
optical microscopy
electron microscopy
x-ray diffraction
Auxiliary methods are also applicable to help identification or to enhance mineral
concentration in the sample:
The main quantitative analysis techniques (also called modal analysis) are:
stoichiometric balance
Mineral Classification
In classical mineralogy, chemical composition and internal structure have been the basis for
the classification of minerals. Dana's Classification, shown in Table 1 below, is widely
accepted.
In process mineralogy, minerals are classified by their uses or functions, as shown in Table 2
below.
Table 4 - Minerals Classified by Use / Functions
Classes
ore minerals
industrial minerals
energy minerals
gemstones
gangue minerals
Use / Function
Examples
metals extraction
CuFeS2
power generation
coal
jewelry
diamond
clayminerals
Examples
Gold, Au
Pyrite, FeS2
Enargite, Cu3AsS4
Oxides/Hydroxides
Halides
Fluorite, CaF2
Carbonates
Calcite, CaCO3
Nitrates
Nitratite, NaNO3
Borates
Borax, Na2B4O5(OH)4.8H2O
Phosphates
Apatite, Ca5(PO4)3(F,Cl,OH)
Sulfates
Tungstates
Silicates
Barite, BaSO4
Scheelite, CaWO4
Plagioclase, NaAlSi3O8-CaAl2Si2O8
From the process and environmental perspective, all minerals must be known and their
properties characterized. For instance, knowing the type of gangue-minerals, we can predict
the acid neutralization potential of a tailing.
In this case, we must identify the main mineral factors.
Mineral Factors
Mineral Factors
Mineral factors are important for:
Texture has implications for liberation processes. Intergrown or aggregates of minerals are
difficult to liberate. In many circumstances grains of the valuable mineral are completely
inaccessible to reagents. Gold locked in sulfide particles is a common example. A fractured
texture can also facilitate penetration of cyanide into rock fragments in a heap leaching
operation.
Shape of the grains has influence on gravity concentration methods (gold flakes are difficult
to concentrate on shaking tables) and on liberation and reaction rate. This is important for
industrial minerals, e.g. asbestos, CaCO3, etc.
Grain size of minerals has influence on liberation, reaction rates in hydro and
pyrometallurgical processes, recovery of minerals in beneficiation processes and specification
of products. Kaolin to be used as paper coating must have more than 80% of the grains below
2 m.
Mineral Associations. Preferential association of the minerals of interest is important to
predict contamination of products and the liberation process. Weak boundaries between
mineral and gangue particles favor liberation by "detachment".
Mineral Surface. The surface must be exposed enough and not oxidized to be suitable for
flotation. Sulfide floatability is greatly affected by surface oxidation.
Porosity influences reagent consumption in flotation. A rate of reaction of a particle with a
reagent (liquid or gas) also depends on the rate at which this reagent diffuses to the interior of
the particle through pores and cracks and reacts there. Apatite with large number of pores ( <
0.01 m ) is good material for phosphoric acid manufacturing and for direct use as a fertilizer.
Impurities or inclusions determine the quality of the products. Impurities (as solid solution,
unliberated particles, or particles dragged to concentrates) result in large penalties when
concentrates are sold. Silica as inclusion reduces the price of the Zn concentrates (Cn$ 3.00
for each 1% of SiO2 in excess of 2.5%); each 1% of Fe in solid solution in sphalerite (ZnS)
has penalties of Cn$ 1.80; for each 100 ppm Hg ( > 50 ppm) in 1 short ton of Zn concentrate,
the price is reduced Cn$ 3.00 (Cominco Smelter, 1997).
Physical and chemical properties determine the beneficiation process to be selected and the
performance in industrial processes. Properties vary with the chemical composition of
minerals. Rutile (TiO2) in India is magnetic. Zircon in Nigeria is more magnetic than
ilmenite.
Crystal structure. Reactivity of solids to leaching solutions varies from one polymorph to
another. Calcite is more reactive than aragonite. Defects in the structure associated with shape
and type of crystal structure bring special properties for some minerals. Natural -MnO2,
"nsutite", is adequate for dry batteries and -MnO2, "pyrolusite" is not.
Alteration products have a strong effect on all beneficiation processes as well as increasing
reagent consumption in metallurgical processes. Clay minerals mixed with hydrous ferric
oxides form a thin layer on gold particles that prevents flotation. The presence of hydrous
ferric oxides in oxidized copper ores is one of the main sulfuric acid consumers.
Sieve size
(mesh)
Weight retained
(%)
W
(%)
DW
(%)
+6
4.31
0.61
1.79
-6 +8
2.65
0.20
0.36
-8 +10
5.78
2.09
8.22
-10 +14
4.32
3.45
10.1
-14 +20
5.75
4.01
15.7
-20 +28
7.84
4.12
22.0
-28 +35
8.23
2.93
16.4
-35 +48
8.94
2.54
15.4
-48 +65
6.02
0.81
3.32
-65 +100
6.21
0.60
2.53
-100 +150
7.55
0.21
1.08
-150 +200
8.32
0.22
1.25
-200 +270
8.97
0.12
0.73
-270 +400
7.30
0.13
0.65
-400
7.81
0.080
0.43
Total (calculated)
100
1.47
100
Total (analyzed)
1.36
For example, Table 1, above right, shows the particle size and tungsten (W) distribution of a
representative sample of a pegmatite , containing wolframite , crushed below 4 mesh
(4.74 mm).
Clearly, in this ore, wolframite has a tendency to be concentrated in the coarse fraction, but
this does not mean that this mineral is liberated. Classification can eliminate 60% of mass and
concentrate 88% of wolframite.
For example, Au distribution in this ore follows the mass distribution, shown in Figure 2
below. This give us a hint that Au is likely very fine.
Correlation between Cu and Au is a good indication that bulk concentrate of copper minerals
can take gold together, shown in Figure 3 below.
Figure 3. Correlation between Cu and Au is a good indication that bulk concentrate of copper
minerals can take gold together.
For example, Au distribution in Figure 4 below shows some correlation with Ag distribution.
Cu in Figure 5 below shows poor correlation with S due to the presence of different copper
minerals, such as tennantite (Cu,Fe)12As4S13 and mooihoekite Cu9Fe9S16 as well as other
non-copper sulfides such as galena PbS and pyrite FeS2.
Figure 4
Figure 5
Cu shows poor correlation with S due to the presence of different copper minerals.
polarizing film which can be either slid or flipped into the light path. The vibration
direction is set at 90 to the lower polarizer.
a polarizer, which converts non-polarized light from source into plane polarized light
a light source
Figure 2
Refraction
In isotropic substances, such as glass, liquids or crystals that belong to the isometric crystal
system, light moves in all directions with equal velocity and hence each isotropic substance
has a single refractive index, shown in Figure 3 below.
In anisotropic substances, light is broken into two polarized rays vibrating in perpendicular
planes, shown in Figure 4, below.
Figure 3. In isotropic substances light moves in all directions with equal velocity.
In hexagonal and tetragonal (anisotropic) crystals there is only one direction in which
ordinary light moves in the same direction as extraordinary light. This is called the optic axis,
which coincides with the c axis (see Figures 6 and 7 below). These crystals are called
uniaxial. Orthorhombic , monoclinic and triclinic crystals have two optical axes and
they are optically classified as biaxial.
Uniaxial Crystals
Uniaxial crystals, shown in Figure 5 right, are divided into two optical groups: positive and
negative.
Positive: when the O ray has greater velocity than the E ray.
Negative: when the E ray has greater velocity than the O ray.
Figure 5. Uniaxial crystals. A. The uniaxial indicatrix is a geometrical figure that is helpful
in visualizing the relation of the refractive indices and their vibration directions. B. Cross
sections of uniaxial indicatrix. (From: Wahlstrom (1951))
There are many refractive indices in uniaxial crystals, depending on direction. Usually just
the two principal indices are represented and the difference between them is called
birefringence . This is better observed with crossed polars.
Some anisotropic minerals absorb more light (some wavelengths) in one vibration direction
than in the other. This phenomenon is called pleochroism . Examples are tourmaline ,
biotite , and hypersthene .